Riello G5R MC Quick start guide

20013743 (3) - 04/2011
Installation, use and maintenance instructions
安装 , 使用以及维护说明书
Light oil burner
轻油燃烧器
CODE - 编码 MODEL - 型号 TYPE - 类型
20013623 G5R MC 447T1
GB
CN
One stage operation
一段火运行

20013743
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INFORMATION ABOUT THE INSTRUCTION MANUAL
INTRODUCTION
The instruction manual supplied with the burner:
- is an integral and essential part of the product and must not be sepa-
rated from it; it must therefore be kept carefully for any necessary
consultation and must accompany the burner even if it is transferred
to another owner or user, or to another system. If the manual is lost
or damaged, another copy must be requested from the Technical
Assistance Service of the area;
- is designed for use by qualified personnel;
- offers important indications and instructions relating to the installation
safety, start-up, use and maintenance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-
UAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the system manu-
facturer, with the recommendation to keep it in the room where the
heat generator is to be installed.
- The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assistance
Centre;
- The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system is
started up,
- maintenance and the need to have the system checked at least
once a year by the manufacturer or another specialised techni-
cian.
To ensure a periodic check, recommends the drawing up
of a Maintenance Contract.
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1 20013743
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TECHNICAL DATA
BURNER DESCRIPTION
OBurner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,
Machines 2006/42/EC.
OThe burner meets protection level of IP 40, EN 60529.
HYDRAULIC JACK OPERATION 7)(Fig. 1)
TYPE 447T1
Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h
Fuel Light oil, viscosity 4 – 6 mm2/s at 20 °C
(Hi= 11.86 kWh/kg)
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 0.75A – 2800 rpm – 294 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 7 – 15 bar
Absorbed electrical power 0.185 kW
It is strongly recommended a periodic check of the pump pressure operation (annually or better every six
months, if the burner operation is continuous).
If the value is lower than 1 bar, compared to that one of the initial setting, please check the cleaning of the
pump and line filters.
In case the pressure setting was not restorable, please replace the pump, in order to guarantee that the
pump pressure during the pre-purge time is at least 3.7 bar.
1– Return line
2– Suction line
3– Gauge connection
4– Pump pressure regulator
5– Vacuum gauge connection
6– Screws fixing air damper
7– Hydraulic jack with air damper
8– Lock-out lamp and reset button
9– Flange with insulating gasket
10 – Combustion head adjustment screw
Fig. 1
5
D4645 1243
6
6
7
9
108
DANGER

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BURNER EQUIPMENT
Flexible pipes with nipples . . . . . . . . . . . No. 2 Cover . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws and nuts for flange . . . . . . . . . . . No. 4 Hinge . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screw with two nuts for flange . . . . . . . . No. 1 Insulating gasket . . . . . . . . . . . . . . . No. 3
FIRING RATE
OVERALL DIMENSIONS
0.8
0
0.4
Pressure in the combustion
chamber – mbar
2 3 4 5 Light oil output - kg/h
25 30 60 Thermal power - kW
D5226 35 40 45 50 55
0.2
0.6
2.3
270 122 224
130
=
33
45°
ø80
228
11
175
D4646
=
180
75 72
150
45°
Flange Burner

3 20013743
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MOUNTING THE BURNER
It is necessary that the insulating gasket
(9, fig. 1) is placed between the boiler door
and the burner flange.
This insulating gasket has six holes,
which, if necessary, can be modified as
shown on the drawing on the right.
D5242
Fig. 2
Verify that the installed
burner is lightly leaned
towards the button.
(See figure 2).
D5572
BURNER FIXING AND
HINGE ASSEMBLY
S7384

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HYDRAULIC SYSTEMS
Warning: before starting the burner make sure that the return pipe-line is not clogged: any obstruction
would cause the pump seals to break.
The pump vacuum should not exceed a
maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from
the oil.
Oil lines must be completely airtight.
The return line should terminate in
the oil tank at the same level as the
suction line; in this case a non-return
valve is not required.
When the return line arrives over the
fuel level, a non-return valve must be
used.
This solution however is less safe than
previous one, due to the possibility of
leakage of the valve.
PRIMING THE PUMP
Start the burner and wait for the priming.
Should lock-out occur prior to the arrival
of the fuel, await at least 20 seconds
before repeating the operation.
A filter must be installed on the suction fuel line.
H
meters
Lmeters
I. D.
8 mm I.D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
WARNING
The pump is supplied for use with a two pipe system.
For use on a one pipe system, it is necessary to remove the by-pass
screw (A, fig. 3).
A
H
meters
Lmeters
I. D.
8 mm I.D. 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
H max. 4 m
H
H
max. 4 m
min. 0.1 m
D5219
D5220
D5199
H=Difference of level.
L=Max.length of the
suction line.
I.D.=Internal diameter of the
oil pipes.
PRIMING THE PUMP
Loosen the plug of the vacuum gauge (5, fig. 1,
page 1) and wait until the fuel flows out.
Fig. 3

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ELECTRICAL WIRING
ATTENTION:
Do not swap neutral and phase over, follow the diagram
shown carefully and carry out a good earth connection.
The section of the conductors must be at least 1mm². (Unless re-
quested otherwise by local standards and legislation).
The electrical wiring carried out by the installer must be in
compliance with the rules in force in the country.
CONTROL BOX, (see fig. 4)
To remove the control box (1) from the burner:
Unscrew the fissing screws on the burner cover and remove it.
Unscrew the fissing screws (2) on the plate and remove the
control box (1).
Screw the two fissing screws (2) and reassemble the burner
cover.
Fix the control box (1) with plate far from the burner.
TESTING
Check the shut-down of the burner by opening the thermostats.
21
D4677
Key to lay-out
A- Control box 531SE
C- Capacitor
E- Electrode
F-Fuse
FR -P.E.Cell
H- Lock-out signal
I- Main switch
M-Motor
PE - Burner-earth
R- Heater
TL - Limit thermostat
TS - Safety thermostat
Y- Oil valve
Fig. 4

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COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjust-
ment and testing must be carried out observing the instruction manual of the boiler, including verifica-
tion of the CO and CO2concentration in the flue gases, their temperatures and the average
temperature of the water in the boiler.
To suit the required appliance output, fit the nozzle then adjust the pump pressure, the setting of the
combustion head and the air damper opening in accordance with the following table.
The values shown in the table are measured on a CEN boiler (as per EN 267).
They refer to 12.5% CO2at sea level and with light oil and room temperature of 20 °C.
RECOMMENDED NOZZLES: Monarch type R - NS; Delavan type W - A - E;
Steinen type H - Q; Danfoss type H.
Angle:60°:in most cases.
80° : in case of flame detachment, during ignitions at low temper-
atures.
PUMP PRESSURE 12 bar : the pump leaves the factory set at this value
14 bar : improves flame retention; it is therefore suitable for ignitions
at low temperatures.
COMBUSTION HEAD SETTING
This is done when fitting the nozzle, with the blast
tube removed. It depends on the output of the
burner and is carried out by rotating the regulating
rod, till the terminal plane of the blast tube is level
with the set-point, as indicated in the table.
In the figure 5, the combustion head is set for an
output of 0.75 GPH at 12 bar, while the shutter is
level with set-point 2.5, as required by the above
table.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.60 60°/80° 11 2.3 1.5 2
0.65 60°/80° 12 2.6 2 2.2
0.75 60° 12 3.0 2.5 2.5
0.85 60° 12 3.4 3 3
1.00 60° 12 4.0 4 4.5
1.10 60° 12 4.4 5 6
1.25 60° 12 5.0 6 7
SETTINGS CARRIED OUT IN THE FACTORY
0.75 60° S 12 3.0 2.5 2.5
1
2
3
4
1
2
D5582
2
135
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
Fig. 5
3

7 20013743
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Combustion head settings indicated in the table are valid
for most cases. The setting of the fan output according to
the installation should normally be done only through the
air damper. Should one subsequently want to retouch
also the setting of the combustion head (fig. 6), with the
burner running, operate on the rod (1) with a 6 mm span-
ner (2) as follows:
Turn to the right: (sign +):
In order to increase the volume of air entering the com-
bustion chamber and thus diminishing its pressure.
There is a reduction of CO2and the adhesion of the
flame to the air diffuser disc improves. (Setting advisable
for ignitions at low temperatures).
Turn to the left: (sign –):
In order to reduce the volume of air entering the combus-
tion chamber and thus increasing its pressure. The CO2
improves and the adhesion of the flame to the diffuser
tends to reduce. (This setting is not advisable for igni-
tions at low temperatures).
In any case do not bring the combustion head setting
more than one point away from that indicated in the
schedule. One set-point corresponds to 3 turns of the
rod; a hole (3) at its end facilitates counting the number
of turns.
AIR DAMPER ADJUSTMENT, (fig. 7)
The mobile air damper (A) operated by the jack (B) as-
sures the complete opening of the air intake.
The regulation of the air-rate is made by adjusting the
fixed air damper (C), after loosing the screws (D).
When the optimal regulation is reached, screw tight the screws (D) to assure a free movement of
the mobile air damper (A).
The settings indicated in the table refer to the burner with its metal cover fitted and the combustion
chamber with “zero” depression.
These regulations are purely indicative.
Each installation however, has its own unpredictable working conditions: actual nozzle output;
positive or negative pressure in the combustion-chamber, the need of excess air, etc.
All these conditions may require a different air-damper setting.
It is important to take account of the fact that the air output of the fan differs according to
whether the burner has its metal cover fitted or not.
Therefore we recommended to proceed as follows:
– adjust the air damper as indicated in the table;
– mount the cover, simply by means of the upper screw;
– check smoke number;
– should it become necessary to modify the air output, remove the cover by loosening the screw,
adjust the air damper, remount the cover and finally recheck the smoke number.
1
23
6
D5551
D
C
D5555
D
AB
Fig. 6
Fig. 7
4

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FUEL HEATING
In order to obtain smooth starting and operation across
its output range the burner is fitted with an electric
resistance, which heats up the gas oil in the nozzle
line. This resistance is energized when the thermostat
calls for heat and after a delay of approximately two
minutes depending on room temperature, the motor
will start. The resistance remains inserted and locks-
out on the shut-down of the burner.
Attention
Should you want to cut off the electric resistance (on
setting the burner or when the ambient temperature
does not require it, etc. . .), take the plug off the panel
of the control box and plug it into the “Resistance
OFF” (see fig. 8). In this case the burner starts
up when the thermostats close.
NOTE
The warning light (LED) is ON but when the resist-
ance works. It is OFF when the resistance is discon-
nected or broken.
FAILURE DETECTION ON HEATING
DEVICE - Only for type 447T1
The plug fitted in the panel is placed in the position corre-
sponding to “Resistance ON” (see fig. 8).
When the remote control closes, the LED lights up and,
after about two minutes, the burner starts up.
1) If the LED is OFF, the heating resistance placed
in the nozzle-holder is off.
2) If the LED is ON and nevertheless the burner does not run, place the plug in the position corre-
sponding to “Resistance OFF” (see fig. 9). If the motor runs, the delaying device inside
the control box is out of order.
3) If the motor does not run, it means that the failure is neither in the panel nor in the resistance, but
elsewhere.
ELECTRODE SETTING, (see fig. 10)
PLUG
Resistance ON
Resistance OFF LED
S7059
Control box
531SE B
PLUG
Resistance OFF
S7060
LED
Fig. 8
Fig. 9
NORMAL OPERATION
BURNER DOES NOT OPERATE
IMPORTANT:
THESE DIMENSIONS MUST BE
OBSERVED
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
2 – 2.5 mm
4± 0.3 mm
D5230 A
Fig. 10